Submersible water pump having self-contained control circuit

ABSTRACT

A dewatering system includes a selective calibrating sensor circuit configured to receive sensor readings from an electronic sensor, to determine if the electronic sensor is immersed in water, to allow a user to adjust a pump down time in the field, and to generate a control output signal accordingly. The selective calibrating sensor circuit periodically performs a self-calibration when the electronic sensor is not immersed in water to cancel the effect of potential contaminants deposited on the electronic sensor over its operating life. The selective calibrating sensor circuit inhibits calibration when the electronic sensor is immersed in water. In some applications with multiple electronic sensors, the selective calibrating sensor circuit disconnects from one of the electronic sensors before performing the self-calibration. In certain embodiments, a pump control circuit including the selective calibration sensor circuit can be configured to be mounted with a housing of the pump.

CLAIM FOR PRIORITY

This application is a continuation-in-part of U.S. application Ser. No. 12/493,093, filed on Jun. 26, 2009 and entitled METHOD AND APPARATUS FOR SENSOR CALIBRATION AND ADJUSTABLE PUMP TIME IN A DEWATERING SYSTEM, which is a continuation-in-part of U.S. application Ser. No. 12/246,265, filed on Oct. 6, 2008 and entitled METHOD AND APPARATUS FOR SENSOR CALIBRATION IN A DEWATERING SYSTEM; and all of the foregoing applications are hereby incorporated by reference herein in their entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to a dewatering system and, in particular, relates to calibrating a sensor circuit and providing an adjustable pump time in the dewatering system to compensate for accumulative contamination deposited on a sensor that is repeatedly immersed in water over its operating life and to accommodate different size sumps.

2. Description of the Related Art

A dewatering system for an enclosed space, such as a sump pump for an electrical underground vault, often uses a sensor to detect for the presence of water in the enclosed space. The enclosed space is usually subject to waste water accumulation as water from rain, irrigation, leaks, and other sources enter and flood the enclosed space. The sensor is generally mounted at a fixed location in the enclosed space and generates a signal to indicate the presence of water when the sensor is immersed in water. A pump is then activated to remove the water from the enclosed space. The duration that the pump should be activated depends on many factors, including type of pump and size of the enclosed space. One problem with using the sensor in a dirty environment is that there is an accumulative contamination deposited on the sensor each time the sensor is immersed in water. The sensor may become ineffective as its sensitivity is changed by the contamination. Regular maintenance, including periodic cleaning of the sensor, may be required to ensure reliable operations.

SUMMARY OF THE INVENTION

Thus, it would be advantageous to develop a method and an apparatus for calibrating a sensor circuit to cancel out (or ignore) contamination deposited on a sensor that is repeatedly immersed in water during normal operations or providing an adjustable pump down (or activation) time to accommodate different applications. Regular calibration of the sensor circuit reduces the need for cleaning of the sensor which may be placed in a remote or hard to reach location (e.g., inside a transformer vault or an elevator shaft). The adjustable pump down time may be changed in the field or by a user to account for different pumps or sizes of enclosed space.

In one embodiment, a selective calibrating sensor circuit comprises an electronic sensor, a self-calibrating sensing circuit, and a sensor controller. The electronic sensor is configured to provide a sensor reading based on a characteristic of substances in proximity to the electronic sensor. For example, the electronic sensor is a capacitance sensor that generates the sensor reading based on a conductivity of the substances in proximity to the capacitance sensor.

The self-calibrating sensing circuit is configured to receive the sensor reading from the electronic sensor and to generate a water detection signal to indicate whether the electronic sensor is immersed in water based on the sensor reading. During calibration, the self-calibrating sensing circuit improves accuracy of the water detection signal by adjusting one or more internal parameters to null an effect on the sensor reading due to contaminants or non-water substances in contact with the electronic sensor. That is, the self-calibrating sensing circuit reduces its sensitivity to any substance that is in contact with the electronic sensor during calibration.

The sensor controller is configured to receive the water detection signal and to generate a control output signal based on the water detection signal. In one embodiment, the sensor controller is also configured to prohibit calibration by the self-calibrating sensing circuit when the water detection signal indicates that the electronic sensor is immersed in water. The selective calibrating sensor circuit loses its ability to detect water using a particular electronic sensor if calibration occurs when that particular electronic sensor is immersed in water. Therefore, the sensor controller selectively enables calibration by the self-calibrating sensing circuit when the water detection signal does not indicate that the electronic sensor is immersed in water.

In one embodiment, the self-calibrating sensing circuit automatically conducts calibration at power-up and the sensor controller triggers subsequent calibrations in the self-calibrating sensing circuit during normal operations by temporarily interrupting power to the self-calibrating sensing circuit. That is, the sensor controller shuts off power to the self-calibrating sensing circuit for a very short time and then reapplies power to the self-calibrating sensing circuit to trigger calibrations similar to the calibration at power-up. In one application, the self-calibrating sensing circuit is powered by a primary source derived from an external AC power line and a secondary source derived from a local battery that activates during a power outage of the external AC power line to avoid inadvertent calibrations by the self-calibrating sensing circuit. For example, the local battery can be implemented with one or more standard sized (e.g., three AA) alkaline batteries that are embedded in a common potted assembly with the self-calibrating sensing circuit.

In one embodiment, the sensor controller is implemented with a microcontroller chip. The microcontroller chip includes programmable input/output ports and a microprocessor. The microcontroller chip can be programmed to run different calibration algorithms and to generate different control output signals for different applications. In one application, the water detection signal is provided to an input of the microcontroller chip and a calibration algorithm uses one or more timers to generate a pulse signal to periodically trigger calibration in the self-calibrating sensing circuit while the water detection signal does not indicate that the electronic sensor is immersed in water. In some instances, timers (e.g., counters) in the microcontroller chip may have an upper limit and thus limit a trigger period for calibration. A cascade of two or more timers can be used to lengthen the trigger period (i.e., increase an interval between calibrations).

In one application, a control output signal is configured to activate an alarm (e.g., a light or a sound) when the water detection signal indicates that the electronic sensor is immersed in water. For example, the alarm may be used to inform a remote monitoring system of possible problems (e.g., a failed pump) in a dewatering system or to provide visual and audible aid to personnel in the vicinity regarding a status of the dewatering system. In another application, a control output signal is configured to activate a water pump while the water detection signal indicates that the electronic sensor is immersed in water. The control output signal may optionally be configured to continue activating the water pump for a predetermine duration (e.g., eight seconds) after the water detector signal indicates that the electronic sensor is no longer immersed in water. The predetermined duration can be variable (e.g., from seconds to minutes by programming the microcontroller chip) and can be set according to a type of water pump being used, an enclosure's size, and the like. Allowing the water pump to remain active for the predetermined duration after the electronic sensor is no longer immersed in water avoids frequent on/off cycles for the water pump. For example, if the water pump turns off immediately (or relatively too quickly) after the electronic sensor is no longer immersed in water, the electronic sensor remains relatively close to the water level and a relatively small amount of additional water or a physical disturbance may trigger the water pump to become active again.

In one embodiment, a water pump control circuit comprises one or more sensors configured to generate respective sensing signals to indicate type of substance in contact with the respective sensors. A sensing circuit receives the sensing signals and generates detection signals to indicate when any of the sensors is in contact with water. The sensing circuit is selectively disconnected from at least one of the sensors during calibration of the sensing circuit. A controller circuit receives the detection signal and generates a control signal to activate a water pump for at least a programmable duration while any of the sensors is in contact with the water. The controller circuit intermittently enables calibration of the sensing circuit and updates the programmable duration based on user input. In one application, a waterproof and user-adjustable micro-switch with outputs coupled to the controller circuit is used to set the programmable duration.

The sensors may be capacitive sensors mounted at substantially fixed locations in an enclosed space. In one application, the sensors comprise a first sensor configured to detect water at a first level in an enclosed container and a second sensor configured to detect water at a second level above the first level in the enclosed container. The controller circuit disconnects at least the first sensor before enabling calibration of the sensing circuit. In one embodiment, an electronic switch such as a reed relay is coupled between one of the sensors and the sensing circuit to disconnect that sensor from the sensing circuit during calibration of the sensing circuit. For example, the controller circuit can be a microcontroller chip with a programmable calibration algorithm and programmable input/output terminals. One of the programmable output terminals can be used to control the reed relay to disconnect the sensing circuit from at least one of the sensors during calibration of the sensing circuit. By way of example, the programmable calibration algorithm uses one or more timers to periodically trigger calibration of the sensing circuit while the sensors are not in contact with water. Calibration of the sensing circuit may also be triggered when power is initially applied or when power is interrupted.

In one embodiment, a dewatering system comprises a first capacitance probe and a second capacitance probe, and a self-calibrating sensor circuit. The first capacitance probe is configured to detect for the presence of water at a first level in a container. The second capacitance probe is configured to detect for the presence of water at a second level in the container. The self-calibrating sensor circuit is configured to receive respective outputs from the first capacitance probe and the second capacitance probe and to inhibit calibrating itself when the respective outputs indicate that at least one of the first capacitance probe and the second capacitance probe is immersed in water. The self-calibrating sensor circuit is also configured to periodically calibrate itself when the respective outputs from the first capacitance probe and the second capacitance probe indicate that both the first capacitance probe and the second capacitance probe are not immersed in water. During calibration, the self-calibrating sensor circuit adjusts one or more internal reference sensing levels to cancel effects on the respective outputs of the first capacitance probe and the second capacitance probe due to deposits or non-water substances (e.g., contaminants or oil) in contact with the first capacitance probe and the second capacitance probe.

In one application, the second level is higher than the first level, and the self-calibrating sensor circuit generates a control output signal to turn on a water pump when the output of the second capacitance probe indicates that the second capacitance probe is immersed in water and to turn off the water pump when the output of the first capacitance probe indicates that the first capacitance probe is not immersed in water. In one embodiment, an interface circuit is coupled between the self-calibrating sensor circuit and the water pump. The interface circuit includes an isolation and rectification circuit that generates a substantially direct current (DC) voltage from an alternating current (AC) power line to power the self-calibrating sensor circuit. The interface circuit further includes a relay circuit that receives the control output signal. The relay circuit turns on/off the water pump by connecting/disconnecting the water pump from the AC power line through a relay switch controlled by the control output signal. In one embodiment, the water pump is a submersible pump that pumps water out of the container at a level below the first level and the second level.

In some applications, the dewatering system further includes a high liquid alarm system with one or more sensors configured to detect for presence of liquid at a level in the container that is above the first level and the second level. The high liquid alarm system sets off a local alarm or a remote alarm to alert of possible abnormal conditions. For example, water does not normally rise pass the second level unless the water pump is not functioning properly. Other abnormal conditions that can trigger an alarm include excess non-water liquids, such as oil, filling the container. In one embodiment, the high liquid system uses at least one capacitance sensor with its own self-calibrating sensor circuit to provide reliable and substantially maintenance-free operations.

In another embodiment, a dewatering system comprises a primary sensor configured to detect water at a first level in a container and a sensing-controller circuit configured to receive an output of the primary sensor. The sensing-controller circuit turns on a water pump for an adjustable pump-down duration when water is detected at the first level and intermittently disconnects from the primary sensor to perform a self-calibration. For example, an electrical switch is coupled between the primary sensor and the sensing-controller circuit for disconnecting the primary sensor from the sensing-controller circuit during self-calibration of the sensing-controller circuit.

The adjustable pump-down duration is selectable by a user. For example, a multi-position switch can be used to generate a binary number based on a user-adjustable position. The binary number is provided to the sensing-controller circuit to indicate the adjustable pump-down duration. In one embodiment, the dewatering system further comprises a secondary sensor configured to detect water at a second level that can be above or below the first level. The sensing-controller circuit receives an output of the secondary sensor and turns on the water pump for the adjustable pump-down duration or a different duration when water is detected at the second level. The dewatering system may further comprise a high liquid alarm system with one or more sensors configured to detect for presence of liquid at a level in the container that is above the first level and the second level to activate an alarm.

In one embodiment, a method to reliably pump water out of an enclosed container comprises using a first sensor to detect water at a first predetermined level in the enclosed container and using a water pump to remove water below the first predetermined level from the enclosed container. A sensing and control circuit is coupled between the first sensor and the water pump to activate the water pump for a first duration when water is detected at the first predetermined level. The first duration is programmable by a user (e.g., by adjusting a multi-position micro-switch). The method optionally includes a second sensor to detect water at a second predetermined level in the enclosed container. The second sensor is configured to activate the water pump for the first duration or a second duration that is independent of the first duration when water is detected at the second predetermined level.

The sensing and control circuit is intermittently disconnected from the first sensor and the water pump to perform a self-calibration of the sensing and control circuit. For example, a reed relay or other electronic switch can be used to intermittently disconnect the sensing and control circuit from the first sensor. In one embodiment, the self-calibration of the sensing and control circuit comprises incrementing a counter when water is not detected at the first predetermined level, not updating the counter when water is detected at the first predetermined level, calibrating the sensing and control circuit when the counter reaches a predetermined number, and resetting the counter after each calibration. In another embodiment, the self-calibration of the sensing and control circuit comprises incrementing a cascade of two or more counters when water is not detected at the first predetermined level, not updating any of the counters when water is detected at the first predetermined level, calibrating the sensing and control circuit when a final counter in the cascade of two or more counters reaches a predetermined number, and resetting all counters in the cascade of two or more counters after each calibration.

In one embodiment, a method for calibrating a sensor comprises providing a first sensor reading from a first capacitance sensor to a sensing circuit and comparing the first sensor reading with a first reference sensing level in the sensing circuit to generate a first water detection signal that indicates whether the first capacitance sensor is immersed in water. The method further comprises executing a calibration algorithm that disables calibration of the sensing circuit when the first water detection signal indicates that the first capacitance sensor is immersed in water and selectively enables calibration of the sensing circuit when the first water detection signal does not indicate that the first capacitance sensor is immersed in water. The first reference sensing level is adjusted during calibration to effectively cancel errors in the first sensor reading due to accumulative contamination deposited on the first capacitance sensor. The first water detection signal can also be used to generate an output signal to control a water pump or an alarm in a dewatering system.

In one implementation, the calibration algorithm selectively enables calibration of the sensing circuit by periodically shutting off power to the sensing circuit and reapplying power to the sensing circuit after a predefined duration when the first capacitance sensor is not immersed in water. In one embodiment, the calibration algorithm comprises incrementing a counter with a system clock when the first water detection signal indicates that the first capacitance sensor is not immersed in water, calibrating the sensing circuit when the counter reaches a predetermined number, and resetting the counter after each calibration. The counter is not updated when the first water detection signal indicates that the first capacitance sensor is immersed in water. In another embodiment, the calibration algorithm comprises incrementing a cascade of two or more counters with a system clock when the first capacitance sensor is not immersed in water and calibrating the sensing circuit when a final counter in the cascade of two or more counters reaches a predetermined number. All of the counters are reset after each calibration while none of the counters are updated when the first capacitance sensor is immersed in water.

In one application, the method further comprises providing a second sensor reading from a second capacitance sensor to the sensing circuit and comparing the second sensor reading with a second reference sensing level in the sensing circuit to generate a second water detection signal that indicates whether the second capacitance sensor is immersed in water. The calibration algorithm disables calibration of the sensing circuit when the second water detection signal indicates that the second capacitance sensor is immersed in water and periodically calibrates the sensing circuit when the first water detection signal and the second water detection signal indicate that both the first capacitance sensor and the second capacitance sensor are not immersed in water. The second reference sensing level is adjusted during calibration to effectively cancel errors in the second sensor reading due to accumulative contamination deposited on the second capacitance sensor. In one embodiment of a dewatering system, the first water detection signal and the second water detection signal are provided to a pump controller that generates a control output signal to start a water pump when the first water detection signal and the second water detection signal indicate that both the first capacitance sensor and the second capacitance sensor are immersed in water and to stop the water pump when the first water detection signal and the second water detection signal indicate that both the first capacitance sensor and the second capacitance sensor are not immersed in water.

In certain embodiments, the present disclosure relates to a water pump having an electrical motor and a pump mechanism coupled to the electrical motor and configured to pump water from an inlet to an outlet when the electrical motor is turned on. The water pump further includes a housing for the electrical motor, and one or more sensors mounted on the housing and configured to generate respective sensing signals to indicate types of substance in contact with the respective sensors. The water pump further includes a pump control circuit configured to communicate with the electrical motor and the one or more sensors. The pump control circuit is further configured to control operation of the electrical motor based on the sensing signals, and the pump control circuit disposed substantially within the housing.

In certain embodiments, the pump control circuit includes a sensing circuit configured to receive the sensing signals and to generate a detection signal to indicate when any of the sensors is in contact with water. In certain embodiments, the pump control circuit is further configured to receive the detection signal and to generate a control signal to activate the electrical motor for at least a programmable duration while any of the sensors is in contact with water. In certain embodiments, the sensing circuit is further configured to selectively disconnect from at least one of the sensors during calibration of the sensing circuit. In certain embodiments, the pump control circuit is further configured to intermittently enable calibration of the sensing circuit and update the programmable duration based on user input. In certain embodiments, the one or more sensors include a first sensor configured to detect water at a first level and a second sensor configured to detect water at a second level above the first level, and the pump control circuit is configured to disconnect the first sensor before enabling calibration of the sensing circuit.

In certain embodiments, the pump control circuit includes a microcontroller chip with a programmable calibration algorithm and programmable input/output terminals. In certain embodiments, the programmable calibration algorithm is configured to utilize one or more timers to periodically trigger calibration of the sensing circuit while the sensors are not in contact with water.

In certain embodiments, the pump control circuit is on a printed circuit board. In certain embodiments, the housing includes a main body and a cap dimensioned to mate with the main body, with the main body substantially enclosing the electrical motor, and the cap defining an interior space dimensioned to receive at least a portion of the pump control circuit. In certain embodiments, the cap mates with the main body so as to facilitate formation of a substantially water-tight seal between the interior space and outside of the housing.

In certain embodiments, the cap defines a sensor mounting aperture, and the one or more sensors are mounted on the sensor mounting aperture via a sensor housing so as to allow electrical connection of the one or more sensors positioned outside the housing with the pump control circuit positioned within the housing. In certain embodiments, the sensor housing includes a tube having first and second ends, with the first end dimensioned to fit into the sensor mounting aperture, and the second end configured to project the one or more sensors along a direction having a vertical component. In certain embodiments, the tube includes an “L” shaped tube mounted to the cap such that one end of the “L” shaped tube points downward. In certain embodiments, the sensor housing further includes potting material configured to secure the one or more sensors to the tube and provide a substantially water-tight seal between the first and second ends of the tube.

In certain embodiments, the present disclosure relates to a kit that includes a replacement cap dimensioned to replace an existing cap of a housing of a submersible water pump. The replacement cap defines an inner recess and an aperture extending from the inner recess to an outer surface of the replacement cap. The kit further includes one or more sensors configured to be mountable to the replacement cap, with the one or more sensors having electrical leads dimensioned to extend through the aperture when the one or more sensors are mounted to the replacement cap, and the one or more electrical sensors capable of generating respective sensing signals to indicate types of substance in contact with the respective sensors. The kit further includes a pump control circuit configured to be mountable to the replacement cap such that at least a portion of the pump control circuit is within the inner recess, with the pump control circuit dimensioned such that when the replacement cap with the pump control circuit mounted thereto is secured to the housing, the pump control circuit is substantially within the housing.

In certain embodiments, the kit further includes a sealing component configured to facilitate a substantially water-tight seal for the pump control circuit when the replacement cap is secured to the housing. In certain embodiments, the kit further includes a power connection kit configured to allow connection of the pump control circuit to a power source for the submersible water pump to thereby provide power to the pump control circuit. In certain embodiments, the kit further includes a control output connection kit configured to facilitate switching on and off of the submersible water pump by the pump control circuit.

In certain embodiments, the present disclosure relates to a water pump control circuit that includes a sensing circuit configured to receive sensing signals from one or more sensors and to generate a detection signal to indicate when any of the sensors is in contact with water. The sensing circuit is selectively disconnected from at least one of the sensors during calibration of the sensing circuit. The water pump control circuit further includes a controller circuit configured to receive the detection signal and to generate a control signal to activate a water pump for at least a programmable duration while any of the sensors is in contact with water. The controller circuit intermittently enables calibration of the sensing circuit and updates the programmable duration based on user input. The sensing circuit and the controller circuit are on a printed circuit board dimensioned to be mounted within a housing of the water pump, with the printed circuit board configured to receive power from an electrical power source that powers the water pump by one or more electrical connections within the housing, and the printed circuit board further configured to connect the water pump to a switch capable of turning the water pump on or off based on the control signal. The printed circuit board is further configured to connect the one or more sensors to the sensing circuit.

While the invention may be described in various embodiments with reference to a dewatering system, it is intended that the invention also applies to other types of systems that benefit from selective self-calibration to compensate for sensors that become contaminated over time or an adjustable pump down time to accommodate changes in the field. Neither this summary nor the following detailed description purports to define the invention. The invention is defined by the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention will now be described with reference to the drawings summarized below, which are intended to illustrate, and not limit the present invention.

FIG. 1 is a block diagram of one embodiment of a selective calibrating sensor circuit.

FIG. 2 is a schematic of one embodiment of a selective calibrating sensor circuit implemented with a self-calibrating sensing unit and a microcontroller chip.

FIG. 3 is a schematic of one embodiment of an interface circuit between a selective calibrating sensor circuit and a water pump.

FIG. 4 is a flow chart of one embodiment of a sensor calibration process for a pump controller with one sensor probe used in dewatering applications.

FIG. 5 is a flow chart of another embodiment of a sensor calibration process for a pump controller with one sensor probe used in dewatering applications.

FIG. 6 is a flow chart of one embodiment of a sensor calibration process for a pump controller with two sensor probes.

FIG. 7 is a flow chart of another embodiment of a sensor calibration process for a pump controller with two sensor probes.

FIG. 8 is a schematic of one embodiment of an alarm system connectable to a selective calibrating sensor circuit.

FIG. 9 is a flow chart of one embodiment of a sensor calibration process for an alarm system.

FIG. 10 illustrates one embodiment of a submersible pump control system operating in conjunction with a high water alarm system.

FIG. 11 is a block diagram of another embodiment of a selective calibrating sensor circuit.

FIG. 12 is a schematic of another embodiment of a selective calibrating sensor circuit implemented with a self-calibrating sensing unit and a microcontroller chip.

FIG. 13 is a flow chart of one embodiment of a sensor calibration process with an adjustable pump down time.

FIG. 14 shows that in certain embodiments, a pump control circuit can be implemented on a circuit board that is mounted within a housing of the pump.

FIGS. 15A and 15B show different views of one embodiment of a pump cap assembly configured to allow mounting of the pump control circuit within the pump housing.

FIG. 16 shows non-limiting examples of how one or more sensors can be disposed relative to a selected vertical level.

FIG. 17 shows a schematic of another embodiment of a pump control circuit implemented with a self-calibrating sensing unit and a microcontroller chip on the enclosed circuit board of FIG. 14.

DETAILED DESCRIPTION

A dewatering system, and a selective calibrating sensor circuit used in the dewatering system with an adjustable pump down time, will now be described with reference to the drawings. This description is intended to illustrate preferred embodiments of the invention, and not limit the invention. The invention is defined by the claims.

FIG. 1 is a block diagram illustrating one embodiment of a selective (or intelligent) calibrating sensor circuit comprising a sensing circuit 12 and a sensor controller 14. The sensing circuit 12 receives sensor readings from one or more electronic sensors 10. In one application, the electronic sensors 10 are placed in a dewatering system to detect for the presence of water. The electronic sensors 10 may also be configured to distinguish between water and a non-water liquid such as oil. The sensing circuit 12 compares the sensor readings from the electronic sensors 10 with respective internal reference sensing levels to generate one or more respective water detection signals. The water detection signals are provided to the sensor controller 14. The sensor controller 14 generates one or more control output signals and a calibration enable signal to control calibration of the sensing circuit 12 based on the water detection signals. The sensor controller 14 is optionally programmable (e.g., by a manufacturer or by a user) to perform different calibration routines and/or to generate different types of control output signals for different applications. For example, one or more controls inputs, such as computer instructions and/or logical input control signals, may be provided to the sensor controller 14 to define algorithms and/or logical functions for generating the calibration enable signal and the control output signals.

In one embodiment, the sensing circuit 12 automatically calibrates itself upon power-up. To prevent unintended calibrations, the sensing circuit 12 has at least one backup power source. By way of example, the sensing circuit 12 in FIG. 1 is powered by a primary source and a secondary source that takes over in the event that the primary source is absent. The primary source may be derived (e.g., rectified and/or regulated) from an external AC power line while the secondary source is a locally placed battery. The secondary source is normally inactive but becomes active for continuous operation of the sensing circuit 12 in the event that the primary source has a power outage.

In one application, the sensor controller 14 triggers calibration in the sensing circuit 12 by temporarily disrupting power to the sensing circuit 12. For example, the calibration enable signal can be a pulse signal with an inactive phase that allows the primary source or the secondary source to power the sensing circuit 12 and an active phase that blocks both the primary source and the secondary source from powering the sensing circuit 12. At the end of the active phase for the calibration enable signal, power is reapplied to the sensing circuit 12 to cause the sensing circuit 12 to automatically perform a self-calibration. In one embodiment, the calibration enable signal periodically has an active phase to trigger calibration in the sensing circuit 12 when the electronic sensors 10 are not immersed in water as indicated by the water detection signals. In other words, the sensor controller 14 inhibits (or disables) calibration of the sensing circuit 12 when any one of the electronic sensors 10 is immersed in water and enables periodic calibration of the sensing circuit 12 when all of the electronic sensors 10 are not immersed in water. The periodicity (or frequency) of the calibration enable signal are programmable or selectable through the control inputs.

During self-calibration, the sensing circuit 12 adjusts the internal reference sensing levels with respect to the sensor readings from the electronic sensors 10. When the electronic sensors 10 are out of the water, the sensor readings primarily reflect the contamination deposited (or surface contamination) on the electronic sensors 10. The sensing circuit 12 adjusts the internal reference sensing levels to cancel out the portion of the sensor readings due to contamination deposited on the electronic sensors 10. The sensing circuit 12 effectively ignores the contamination deposited on the electronic sensors 10 after the self-calibration. In some applications, the sensing circuit 12 is also allowed to calibrate when the electronic sensors 10 are immersed in non-water liquids, such as oil.

In other applications, the sensing circuit 12 is allowed to calibrate when the electronic sensors 10 are immersed in water by selectively disconnecting at least one of the electronic sensors 10 from the sensing circuit 12. By way of example, FIG. 11 is a block diagram illustrating another embodiment of a selective calibrating sensor circuit (or sensor-controller circuit) comprising a sensing circuit 112 and a sensor controller 114 that permits sensors to be in water during calibration. Similar to the selective calibrating sensor circuit of FIG. 1, the sensing circuit 112 receives sensor readings from one or more electronic sensors 110 to generate one or more respective water detection signals. The sensor controller 114 then generates one or more control output signals and controls calibration of the sensing circuit 112 based on the water detection signals. In particular, the sensor controller 114 generates a sensor enable signal and a calibration enable signal to selectively disconnect the sensing circuit 112 from at least one of the electronic sensors 110 during calibration of the sensing circuit 112. The configuration shown in FIG. 11 uses one power source to power both the sensing circuit 112 and the sensor controller 114. The configuration of FIG. 11 does not have a secondary power source for the sensing circuit 112 to prevent unintended calibrations.

Similar to the sensor controller 14 described above, the sensor controller 114 is optionally programmable to perform different calibration routines and to generate different types of control output signals. In addition, the sensor controller 114 can be programmed during manufacturing or out in the field to adjust a pump down time (e.g., a pump delay) in dewatering applications. For example, the pump down time can be adjusted from seconds to minutes to accommodate different basin sizes and types of pumps. This feature is especially beneficial when one sensor is used to trigger a water pump.

FIG. 2 is a simplified schematic to show one example of a selective calibrating sensor circuit implemented with a self-calibrating sensing integrated circuit (IC) U2 and a microcontroller chip U3. In one implementation, components for the selective calibrating sensor circuit can be placed on a 1″ by 2″ printed circuit board with a finished circuit assembly height of less than a quarter inch (e.g., about 0.15″ in one embodiment). By way of example, the simplified schematic of FIG. 2 also shows input/output pads/connectors (E1-E12) and edge connections (1-12) on the printed circuit board for electrical connections to other parts or circuit boards.

In one embodiment, the self-calibrating sensing IC U2 is a sensor IC with digital signal processing and self-calibrating capabilities, such as Quantum QT220. The self-calibrating sensing IC U2 includes one or more input terminals (e.g., SNS1A, SNS1K, SNS2A, SNS2K) configured to receive inputs from one or more electronic sensors (e.g., Probe-1, Probe-2) and to generate respective water detection signals (e.g., OUT1, OUT2). The water detection signals are provided to respective input terminals (IN1, IN2) of the microcontroller chip U3. The microcontroller chip U3 includes a microprocessor, programmable inputs/outputs, pulse generators, and timers with an on-chip oscillator to generate customized application programs. In a dewatering application, the microcontroller chip U3 runs a programmable algorithm to generate a calibration enable signal (CAL_EN) and a control output signal (CTRL_OUT) based on the water detection signals. For example, the microcontroller chip U3 may have one or more programmable terminals (PR1, PR2) configured to receive computer instructions and/or logical commands to define a calibration algorithm and a control algorithm for a particular application. That is, instructions can be provided to the programmable terminals to define logical functions between the calibration signal, the control output signal, and the water detection signals. To provide flexibility for electrical interface to subsequent devices, the control output signal from the microcontroller chip U3 is provided to a pair of transistors (Q1, Q2) configured to generate both a logical high output (pull up output) and a logical low output (pull down output) when the control output signal is active (or logic high).

In the configuration shown in FIG. 2, a first set of input pads (E6, E7) is configured to receive a first DC supply voltage (e.g. +/−12 Vac from an AC adapter) and a second set of input pads (E11, E12) is configured to receive a second DC supply voltage (e.g., voltage from a battery). The first DC supply voltage is provided to a power terminal (VDD) of the self-calibrating sensing IC U2 via serially connected resistors (R4, R5) with an isolation diode D1 inserted in between the resistors. The second DC supply voltage is provided to the power terminal of the self-calibrating sensing IC U2 via one of the resistors (R5) such that the self-calibrating sensing IC U2 is normally powered by the first DC supply voltage and alternately powered by the second DC supply voltage in the event that the first DC supply voltage suffers a power outage. The first DC supply voltage may also be provided to a voltage regulator U1 to generate a voltage of a different level for other components on the printed circuit board. For example, an output of the voltage regulator U1 is provided to a power terminal (VDD) of the microcontroller chip U3.

In one embodiment, the calibration enable signal from the microcontroller chip U3 is coupled to the power terminal of the self-calibrating sensing IC U2 via a pull-down transistor Q3. When the calibration enable signal is active (e.g., logic high), the pull-down transistor Q3 grounds the power terminal of the self-calibrating sensing IC U2 (i.e., effectively disrupts power to the self-calibrating sensing IC U2). When the calibration enable signal becomes inactive again (e.g., logic low), the power terminal of the self-calibrating sensing IC U2 receives power from the first DC supply voltage or the second DC supply voltage again and automatically calibrates itself. In one calibration algorithm, the calibration enable signal periodically pulses when the water detection signals indicate that the electronic sensors are not immersed in water. Each pulse temporarily interrupts power to the self-calibrating sensing IC U2 and triggers a self-calibration at the end of each pulse.

FIG. 12 is a simplified schematic to show another example of a selective calibrating sensor circuit implemented with the self-calibrating sensing IC U2 and the microcontroller chip U3. Similar to the embodiment shown in FIG. 2, the self-calibrating sensing IC U2 has input terminals (e.g., S1A, S1K, S2A, S2K) configured to receive inputs from electronic sensors (e.g., Probe-1, Probe-2). In one application, the electronic sensors are mounted at predetermined locations in an enclosed space to detect water. For example, a primary sensor (e.g., Probe-1) can be mounted to detect water at a first level while a secondary (or redundant) sensor (e.g., Probe-2) is mounted to detect water at a second level that is above (e.g., about one inch above) the first level. In one embodiment, only one sensor is needed for dewatering applications, and the secondary sensor operates independently of the primary sensor to provide fail safe operation.

In one embodiment, an electronic switch such as a reed relay K2 is coupled in series between one of the sensors (e.g., Probe-1) and the associated input terminals of the self-calibrating sensing IC U2. The reed relay K2 is controlled by a sensor enable signal (SENSOR_EN) from the microcontroller chip U3 to selectively disconnect the self-calibrating sensing IC U2 from the sensor during calibration. The microcontroller chip U3 outputs a calibration enable signal (CAL_EN) to a reset terminal of the self-calibrating sensing IC U2 to periodically trigger a self-calibration when the electronic sensors are not in contact with water. However, self-calibration may also be triggered when power (e.g., VDD) to the self-calibrating sensing IC U2 is interrupted. The self-calibrating sensing IC U2 and the microcontroller chip U3 share the same power source. When power is lost and then restored, some of the electronic sensors may be in contact with water and introduce errors in the self-calibration. Thus, the microcontroller chip U3 initially disconnects the self-calibrating sensing IC U2 from at least one of the electronic sensors to ensure an accurate calibration with respect to at least one of the sensors. Calibration with respect to the remaining sensors can be corrected in a subsequent self-calibration triggered by the calibration enable signal.

The self-calibrating sensing IC U2 generates water detection signals (e.g., OUT1, OUT2) that are provided to respective input terminals (e.g., IN1, IN2) of the microcontroller chip U3. As discussed above, the microcontroller chip U3 runs a programmable algorithm to generate the calibration enable signal (CAL_EN) and a control output signal (CNTRL_OUT) based on the water detection signals. For example, the control output signal can be used to trigger a water pump when any of the electronic sensors are in contact with water as indicated by the water detection signals. In one embodiment, the water pump turns one when any of the electronic sensors contact water and remains on for an adjustable pump down time after the electronic sensors are no longer in contact with water.

In the embodiment shown in FIG. 12, the adjustable pump down time can be programmed by way of a multi-position micro-switch S1. For example, a user can adjust or select the position on the micro-switch S1 (e.g., a 16-position micro-switch) to generate a corresponding binary number (e.g., a 4-bit binary number or D1-D4) that is decoded by the microcontroller chip U3 to control or adjust the adjustable pump down time. The adjustable pump down time may be associated with one or all of the electronic sensors. Some of the electronic sensors may have pump down times that are predefined during manufacturing or the pump down times may be independently adjusted for each of the electronic sensors (e.g., by using additional micro-switches).

FIG. 3 is a schematic of one embodiment of an interface circuit between a selective calibrating sensor circuit and a water pump. By way of example, the interface circuit (or relay board) includes a rectifier circuit and a relay circuit. The rectifier circuit receives an AC input voltage (e.g., 120 Vac or 240 Vac) from a power line and generates the first DC supply voltage (e.g., +12 Vdc) to serve as a primary power source for the selective calibrating sensor circuit. The rectifier circuit includes a transformer T1 with primary windings coupled to the AC input voltage and secondary windings coupled to a pair of rectifier diodes (D4, D5) to generate the first DC supply voltage. The primary windings have jumpers (EA, EB, EC, ED) that can be configured for operation with a 120 Vac power line or a 240 Vac power line.

The relay circuit includes a relay K1 comprising a relay coil and a relay switch. The relay coil is coupled between the first DC supply voltage and a control output signal (e.g., pull down output) of the selective calibrating sensor circuit. A clamping diode D6 is coupled across the relay coil. The relay switch is coupled between the AC input voltage and the water pump. While the control output signal is active (e.g., logic low), current flows in the relay coil and the relay switch connects the AC input voltage to the water pump (e.g., a power terminal of the water pump), thereby turning on the pump. Other configurations (e.g., different logic levels or different switching devices) to interface the control output signal with the water pump are possible.

FIG. 4 is a flow chart of one embodiment of a sensor calibration process for a pump controller with one sensor probe used in dewatering applications. The pump controller includes one capacitance sensor, a selective calibrating sensor circuit configured to receive a sensor reading from the capacitance sensor, and a relay circuit configured to receive a control output from the selective calibrating sensor circuit to actuate a water pump. The sensor calibration process starts at step 40 after power up, after a predetermined delay of power up or when an enable signal is provided to the selective calibrating sensor circuit. The sensor calibration process begins by incrementing a counter (or starting a timer) in the selective calibrating sensor circuit at step 41.

At step 42, the sensor calibration process determines if the counter is equal to a predefined threshold (T1) corresponding to a desired interval between calibrations. If the counter is equal to the predefined threshold, calibration is enabled at step 45 and the counter is reset at step 46 before the sensor calibration process returns to step 41. If the counter is not equal to the predefined threshold, the sensor calibration process determines if the capacitance sensor is immersed in water at step 43. If the capacitance sensor is immersed in water, the pump controller actuates the water pump for a predetermined duration (X) before returning to step 43. If the capacitance sensor is not immersed in water, the sensor calibration process returns to step 41. Thus, the sensor calibration process described in FIG. 4 periodically enables calibration of the selective calibrating sensor circuit when the capacitance sensor is not immersed in water and suspends (or inhibits) calibration while the capacitance sensor is immersed in water. The frequency of the calibration while the capacitance sensor is not immersed in water is determined by the predetermined threshold (T1). The ordering of the steps can be varied to achieve the same function.

FIG. 5 is a flow chart of another embodiment of a sensor calibration process for a pump controller with one sensor probe. The sensor calibration process in FIG. 5 is similar to the sensor calibration process shown in FIG. 4 with an additional counter (Counter₂) arranged in a cascaded configuration with a first counter (Counter₁). In some implementations, the sensor calibration process is executed by a microcontroller comprising counters with upper limits. The cascaded arranged of two or more counters can be used to provide a combined higher upper limit (e.g., a product of T1 and T2) and allow for a longer interval between calibrations. For example, the calibration frequency while the sensor probe is not immersed in water is determined by a mathematical product of T1 and T2 (e.g., inversely proportional to the mathematical product of T1 and T2).

FIG. 6 is a flow chart of one embodiment of a sensor calibration process for a pump controller with two sensor probes. For example, some pump controllers use two sensor probes (e.g., capacitance sensors) mounted at different levels to control on/off operations of a water pump. The water pump turns on when water reaches the capacitance sensor mounted at a higher level and turns off when the capacitance sensor mounted at a lower level no longer senses water. The sensor calibration process in FIG. 6 determines if both sensor probes are out of the water at step 61. If both sensor probes are out of the water, a counter increases at step 62 and the sensor calibration process determines if the counter is equal to a predefined threshold at step 63. Calibration is enabled at step 64 and the counter is reset at step 65 before returning to step 61 if the counter is equal to the predefined threshold. If the counter is not equal to the predefined threshold, the sensor calibration process returns to step 61.

If both sensor probes are not out of the water at step 61, the sensor calibration process determines if both sensor probes are immersed in water at step 66. If both sensor probes are not in the water, the sensor calibration process returns to step 61. If both sensor probes are in the water, the sensor calibration process effectively inhibits calibration and outputs a control signal at step 67 to turn on the water pump. After turning on the water pump at step 67, the sensor calibration process determines if the sensor probe mounted at the lower level is still immersed in water. The water pump stays on as long as the lower sensor probe is still immersed in water. Once the lower sensor probe is not in water, the sensor calibration process returns to step 61. Thus, the sensor calibration process described in FIG. 6 periodically enables calibration when both sensor probes are out of water, activates the water pump when both sensor probes are immersed in water, and continue to run the activated water pump until the lower sensor probe is no longer immersed in water.

FIG. 7 is a flow chart of another embodiment of a sensor calibration process for a pump controller with two sensor probes. The sensor calibration process of FIG. 7 functions similarly to the sensor calibration process of FIG. 6 and includes additional timers to potentially increase the interval (or reduce the frequency) between calibrations while the sensor probes are not immersed in water. Variations of the steps shown in FIGS. 6 and 7 are also possible.

FIG. 13 is a flow chart of one embodiment of a sensor calibration process for a pump controller (or pump switch) with an adjustable pump down time. The pump controller includes one or more sensor probes configured to detect water, a sensing circuit coupled to outputs of the sensor probes, and a microcontroller configured to generate control signals for the sensing circuit and a water pump. The sensor calibration process starts at step 130 after power up, after a predetermined delay of power up or when an enable signal is provided to the pump controller. The sensor calibration process begins by disconnecting at least one of the sensor probes from the sensing circuit before enabling calibration of the sensing circuit at step 131.

At step 132, the sensor calibration process pauses, reconnects the disconnected sensor probe, and resets one or more calibration counters (e.g., in the microcontroller). At step 133, the sensor calibration process updates the adjustable pump down time (or predefined pump down time) which can be changed or defined by a user after installation of the pump controller in the field. At step 134, the sensor calibration process determines if any of the sensor probes are in contact with water. If any of the sensor probes are in contact with water, the pump controller activates the water pump for the predefined pump down time at step 137 and continues to monitor whether any of the sensor probes are still in water at step 138. If at least one of the sensor probes is still in water at step 138, the sensor calibration process returns to step 137. Thus, the water pump is activated for at least the predefined pump down time when any one of the sensor probes comes in contact with water and continues to pump for the predefined pump down time after the sensor probes are no longer in contact with water.

If none of the sensor probes are in contact with water at step 138, the sensor calibration process returns to step 133. If none of the sensor probes are in contact with water at step 134, the sensor calibration process updates a first counter at step 135. At step 136, the sensor calibration process determines if the first counter is equal to a first predefined threshold (T1). If the first counter is not equal to the first predefined threshold, the sensor calibration process returns to step 133. If the first counter is equal to the first predefined threshold, the sensor calibration updates a second counter at step 139 before proceeding to step 140 to determine if the second counter is equal to a second predefined threshold (T2). If the second counter is not equal to the second predefined threshold, the sensor calibration process returns to step 133. If the second counter is equal to the second predefined threshold, the sensor calibration process proceeds to step 141 to disable the water pump before returning to step 131.

The example sensor calibration process of FIG. 13 uses a cascade of two counters to set a calibration interval. Using only one counter or additional counters are also possible. Similar to the processes described above, variations of the steps are also possible to achieve the same functions.

In some dewatering applications, a capacitance sensor is used to sense for the presence of water and to activate an alarm rather than a water pump. FIG. 8 is a schematic of one embodiment of an alarm system connectable to a selective calibrating sensor circuit. In one application, the capacitance sensor and an optical sensor are co-located with the optical sensor configured to detect for the presence of liquid and the capacitance sensor configured to determine if the liquid is water or oil. The capacitance sensor is coupled to the selective calibrating sensor circuit which generates a control output signal based on sensor readings from the capacitance sensor.

The control output signal from the selective calibrating sensor circuit is provided to a first input terminal (e.g., J1-1 or Smart switch input) of an alarm circuit board. The optical sensor provides an output to a second input terminal (e.g., J1-4 or Optical sensor input) of the alarm circuit board. When the optical sensor detects liquid, the output of the optical sensor activates a first transistor Q1 to provide power (e.g., 12 Vdc) to the alarm circuit board and thereby activating a third transistor Q3 to light up an oil lamp B2 to indicate the presence of oil by default. If the control output signal from the selective calibrating sensor circuit is active (e.g., logic high), indicating that the capacitance sensor is immersed in water, the control output signal activates a second transistor Q2 to turn on a water lamp B1 and consequently deactivates the third transistor Q2 to turn off the oil lamp B2.

In the embodiment shown in FIG. 8, the output of the optical sensor is also provided to activate a buzzer circuit BZ1 and to solid state relay circuits K2, K3, K4 configured for sending alarms to a remote location. The control output signal is also provided to a separate solid state relay circuit K1 configured for sending an alarm to the remote location. The alarm circuit board in FIG. 8 also includes an isolation and rectification stage comprising a transformer T1 and rectifying diodes D1, D2 configured to generate a DC supply voltage (e.g., 12 Vdc) from an AC supply voltage (e.g., 120 Vac or 240 Vac) provided by a power line.

FIG. 9 is a flow chart of one embodiment of a sensor calibration process for an alarm system similar to the one shown in FIG. 8. The sensor calibration process shown in FIG. 9 is a variation of the sensor calibration process shown in FIG. 4. That is, the steps are ordered differently to achieve a similar function of enabling calibration when the capacitance sensor is not immersed in water and inhibiting calibration when the capacitance sensor is immersed in water. In FIG. 4, the water pump is activated at the same time that calibration is inhibited at step 44. In FIG. 9, an alarm (e.g., a local light or a signal to a remote location) would be activated while calibration is inhibited at step 94.

FIG. 10 shows in more detail one embodiment of a submersible pump control system 160 operating in conjunction with a high water alarm system 104. The submersible pump control system 160 includes a submersible pump 106 and a submersible pump controller 164 in an enclosed space. The pump controller 164 is operatively interconnected to the pump 106, configured to activate and deactivate the pump 106 based on present conditions, as described below. The pump controller 164 utilizes sensors which may include, but are not limited to, capacitance-based sensors, conductivity probes, dielectric sensors, and/or combinations thereof, to detect the presence or absence of water and oil. In one preferred embodiment, the pump controller 164 utilizes a capacitive-based sensor to detect the presence of oil and water, as described in U.S. Pat. No. 5,856,783. It will be appreciated that the pump controller 164 may be used in connection with a variety of pumps without departing from the scope of the invention.

As shown in FIG. 10, the pump controller 164 in a preferred embodiment possesses a pair of capacitive sensors 170 to detect the presence of water. Contaminants may accumulate on the capacitive sensors 170 over time. Outputs from the capacitive sensors 170 are provided to a selective calibrating sensor circuit in the pump controller 164. The selective calibrating sensor circuit periodically calibrates itself while the capacitive sensors 170 are out of water to desensitize the pump controller 164 to the potential contaminants on the capacitive sensors 170. The pump controller 164, in one embodiment, is electrically connected to the pump 106, interposed by an electronic relay 172. Activation of the pump 106 occurs when both capacitive sensors 170 are immersed or submerged, such as approximately at a high water level 174 a, and the presence of water is detected by the pump controller 164. In this case, the pump controller 164 communicates with the relay 172 to activate an electronic switch, resulting in a flow of electrical power to the pump 106, which turns the pump 106 on. Deactivation of the pump 106 may occur when both capacitive sensors 170 are out of the water, such as approximately at a low water level 174 b or when oil is detected in the water. In this case, the pump controller 164 communicates with the relay 172 to deactivate the electronic switch and to cease the flow of electrical power to the pump 106, turning the pump 106 off. An adjustable deadband is further provided in the pump controller 164, to avoid the pump 106 turning on and off with slight changes in the water level.

As further illustrated in FIG. 10, when the alarm system 104 is utilized in conjunction with the pump control system 160, the alarm system 104 is installed in a location such as above the high water line 174 a of the pump control system 160. In this manner, should the pump 106 fail to activate when water reaches the high water line 174 a and the water level reach a critical water level 174 c at which sensors 102 of the alarm system 104 are located, the alarm system 104 will then detect the presence of water and oil and issue the appropriate alarms. In one embodiment, the sensors 102 include an optical sensor configured to detect for the presence of liquid at the critical water level 174 c and a capacitance sensor configured to differentiate between water and oil at the critical water level 174 c. The capacitance sensor for the alarm system 104 is also subject to contamination over time. Thus, a sensing circuit board for the alarm system 104 includes a self-calibrating sensing IC to cancel the effects of possible contamination deposited on the capacitance sensor.

Advantageously, the type of alarms raised by the alarm system 104 of the preferred embodiments may inform monitors of the nature of the problem in the enclosed space. A first alarm, indicating the presence of water, may imply a mechanical malfunction resulting in failure of the pump control system 160 to engage at the high water level 174 a. Thus, this alarm may inform monitors that repair personnel should be dispatched to the location to fix the pump 106 and/or pump controller 164. A second alarm, indicating the presence of oil, in conjunction with the first alarm would imply that the pump control system 160 is functioning properly, as the pump control system 160 did not activate the pump 106 at the high water level 174 a, and further inform monitors that oil is present in the enclosed space. Thus, this alarm may inform monitors that clean-up personnel should be dispatched to remove oil from the site so as to allow pumping of water from the site. Therefore, the alarm system functions both as a fault redundant system, alerting monitors that the water level has passed the high water level 174 a, and also as a diagnostic tool, informing monitors of possible causes for why the water level has risen above the high water level 174 a. In this manner, mechanical problems leading to water accumulation in enclosed spaces may be quickly identified, diagnosed, and remedied, saving time and money.

In various examples described herein in reference to FIGS. 1-13, a pump controller (e.g., 164 in FIG. 10) having one or more sensors is described as being a separate unit interconnected with a pump (e.g., 106 in FIG. 10). In certain embodiments, such a pump controller can be mounted to a pump output conduit; and such mounting can be configured so as to provide, among others, adjustability in vertical positions of the sensors. For example, in situations where the pump output conduit is a vertically oriented pipe, the pump controller can be mounted along a range of vertical positions on the pipe via mounting mechanisms such as straps.

In certain situations, however, it may be desirable to provide some of all of the features associated with the pump controller in a configuration that does not require separate mounting of the pump controller and/or use of the external interconnection between the pump controller and the pump. In certain embodiments, such a configuration can be achieved by positioning the pump control circuit within a housing of the pump and interconnecting the enclosed circuit with the one or more sensors configured to be mountable to the pump housing.

When the pump control circuit and the sensors are integrated with the pump, a number of advantageous features can be attained. For example, overall handling and installation of the sensing/pumping system is simplified, since separate mounting of the external pump controller unit and external interconnection with the pump are no longer needed. In another example, since the external pump controller unit is no longer present, concerns associated with protecting the control circuit from the external elements such as water can also be removed. Further, an interface between the external interconnection and the external pump controller's housing is also exposed to the external elements and can be a weak point susceptible to degradation and failure.

It should be noted that even if the pump control circuit is positioned within the pump, the pump itself is still subject to the external elements such as water. In certain embodiments, however, housing for the pump can be substantially more robust than that of an external pump controller, and such protection for the pump's electrical motor can also provide protection for the pump control circuit.

In certain embodiments as described herein, the pump control circuit and the sensors can be mounted to a cap that can replace an existing access cap on the pump housing. Such a replacement cap can be configured to mate with the pump housing so as to provide similar robust protection from the external elements as that of the original cap. Various examples of features that facilitate such robustness in replacement cap assembly (or an OEM cap assembly with a pump control circuit and one or more sensors), as well as sensor configuration considerations, are described in reference to FIGS. 14-17.

FIG. 14 shows that in certain embodiments, one or more circuits 206 associated with a pump controller (e.g., 164 in FIG. 10) can be positioned within a housing 202 of a pump assembly 200. In certain embodiments, such positioning of the circuit 206 can be facilitated by a pump housing cap 204 configured to accommodate the circuit 206 and coupling of the circuit 206 with a sensor assembly 208.

In FIG. 14, the pump assembly 200 is shown to be coupled to a pump output conduit 212. Such coupling can be achieved in one or more known manners. As further shown in FIG. 14, pump assembly 200 including the pump control circuit 206 can be powered via a cable 210. Thus, in certain embodiments, the pump assembly 200 does not require an external component such as the pump controller 164 in FIG. 10. Further, a need for external circuitry (e.g., relay 172 in FIG. 10) can also be removed.

In certain embodiments, the pump control circuit 206 can be configured to provide one or more functionalities as described herein in reference to FIGS. 1-13, including various calibration functionalities and/or those associated with sensing and operation of the pump.

FIG. 15A shows an example embodiment of the pump housing cap 204 with the pump control circuit 206 mounted in a recess 222 defined by the cap 204. FIG. 15B shows another view of the cap 204 without the circuit 206, showing more clearly the recess 222.

In FIG. 15B, the sensor assembly 208 is shown to be mounted on the cap 204. The example sensor assembly 208 is depicted as having two sensor probes 250 a and 250 b mounted on a sensor housing 230 and connectable to the circuit 206 via electrical leads 252. Non-limiting examples of the sensor assembly are described herein in greater detail.

As is generally understood, many submersible pumps include a removable cap to provide access to internal components such as an electrical motor. In certain embodiments, the pump housing cap 204 can be configured to be a replacement for an existing cap. Alternatively, an existing cap can be modified to accommodate the circuit 206 and sensor assembly 208.

In certain embodiments, the circuit 206 can be connected to and powered from the source that powers the electrical motor. In certain embodiments, the circuit 206 can be interconnected internally to the electrical motor so as to provide on/off control functionality similar to that provided by the electronic relay 172 (e.g., FIG. 10). Such a relay component can be part of the circuit 206 or a separate component between the circuit 206 and the electrical motor. Examples of how the circuit 206 can be powered and implementation of the on/off control functionality of the circuit 206 are described herein in greater detail.

For the foregoing embodiments, the cap 204 can include a mating surface 224 dimensioned to allow mating of the cap 204 with the housing (202 in FIG. 14) of the pump 200. In the example mating surface 224 shown in FIGS. 15A and 15B, four mounting holes 226 are shown to allow mounting and securing of the cap 204 to the pump housing 202 via, for example, screws. Preferably, the mating surface 224 is configured so as to facilitate sealing capability. For example, the mating surface 224 can be sufficiently smooth and wide so as to allow use of a sealing gasket and/or sealing compound.

As shown in FIGS. 15A and 15B, the cap 204 can include an opening formed on its wall 220 and dimensioned to receive a portion of the sensor housing 230. By way of an example, the opening and the portion of the sensor housing 230 can be provided with matching threads to allow mounting of the sensor housing 230 to the cap 204. A sealing compound such as a sealant or plumbing tape can be utilized to provide sealing capability.

In certain embodiment, the sensor assembly 208 can be pre-fabricated and mounted to the cap 204. In the example sensor assembly 208 shown in FIG. 15B, potting material can be provided to secure the probes 250 within the sensor housing and to provide sealing functionality.

In the example configuration shown in FIG. 10, the height of the sensors 170 can be adjusted by adjusting the height of the pump controller on the pump output conduit. Preferably, the sensors 170 are positioned so as to provide a vertical spacing of at least about 1.5″ between the lower sensor and the impeller level.

In the example configuration of FIG. 14, where the sensors are mounted to the pump cap, vertical positioning of the sensors at desired levels can be achieved in a number of ways. FIG. 16 shows non-limiting examples of how one or more sensors can be positioned relative to some level of the pump.

In various examples of sensor configurations described herein, two probes can be provided to allow detection of two separate levels of liquid. It will be understood, however, and as shown in an example configuration 260 b, that one or more features relating to the pump cap assembly as described herein can also be implemented where the sensor assembly has one probe 250. Other number of probes can also be implemented.

In an example configuration 260 a, the sensor housing 230 and the sensor probes 250 are shown to be configured such that tips of the two sensor probes 250 are at distances h1 and h2 relative to a reference level such as the mating surface of the pump cap. Since the mating surface is generally fixed relative to other parts (e.g., impeller) of the pump when the cap is secured to the pump, the probe levels h1 and h2 effectively define their relative vertical position relative to the pump.

In certain situations, it may be desirable to lower the probes relative to the pump. To achieve such a configuration where h1 and h2 are increased, an example configuration 260 c can be implemented where the sensor housing 230 is lengthened vertically.

In certain situations where the probes need to be raised to levels beyond those allowed by shortening the sensor housing 230, an example configuration 260 d shows that the sensor assembly can be inverted. In such an inverted configuration, roles of the two probes can be reversed so that the shorter probe facilitates the low level condition (at h1 above the reference level) and the longer probe facilitates the high level condition (at h2 above the reference level).

An example configuration 260 e shows that in certain embodiments, the sensor probes 250 can be mounted to the sensor housing 230 so as to have vertical adjustability (depicted as arrow 272). In the example, the probes 250 are shown to be mounted to a movable member 270 that is movably coupled to a stationary member 274. Movable coupling between the two members (270, 274) can be achieved in a number of known ways.

As shown, movement between the two members (270, 274) can be facilitated by providing slack in an electrical cable or wires that interconnects the probes 250 to electrical leads 278 inside the pump cap. As also shown, potting material 280 can be provided between the stationary member 274 and the interior of the pump cap so as to secure the cable 276 and also to provide sealing functionality.

FIG. 17 shows a schematic diagram of a circuit 290 that can be implemented in the pump control circuit of FIGS. 14 and 15. Generally, various functionalities associated with processing of sensor signals, controlling of the pump, and/or controlling of calibration are similar to those described herein in reference to FIGS. 2 and 12. For example, signal indicators SENSOR_EN, CAL_EN, CNTRL_OUT, VDD, VSS, input/output indicators for the integrated circuit U2 (S1A, S1K, S2A, S2K), and input/output indicators for the microcontroller U3 (IN1, IN2, D1, D2, D3, D4, P1, P2) and their respective components are similar to those shown in FIGS. 2 and 12. Adjustments, additions, or omissions of one or more electronic components associated with the foregoing may be made by one of ordinary skill in the art to yield similar functionalities provided by the circuits of FIGS. 2 and 12.

As previously mentioned, placement of the pump control circuit 290 within the pump housing can involve various modifications from the external pump controller configuration (e.g., FIG. 10). For example, coupling of the sensors to the pump control circuit 290 (depicted as a dotted-line box 310) can be achieved by electrically connecting the sensor leads (e.g., 252 in FIG. 15B) to input/output pads/connectors E1 and E2.

In certain embodiments, the pump control circuit 290 can be configured to be powered from the same source used for powering the electrical motor. In the context of FIG. 17, the electrical motor is assumed to be an AC-motor, and an AC power source is generally depicted by a dotted-line box 300. A transformer (generally depicted by a dotted-line box 302) can be configured to transform the AC power signal to a DC power signal (e.g., 12 VDC signal). As further shown in FIG. 17, the transformer component 302 can be configured to include a fuse F1, as well as jumper junctions to facilitate different voltage AC inputs. For example, connecting EB1 to EC1 by a jumper can facilitate 240 VAC input power; and connecting EA1 to Ec1 and EB1 to ED1 by jumpers can facilitate 120 VAC input power.

In certain embodiments, the pump control circuit 290 can be configured to provide pump switching functionality similar to that of the relay 172 in FIG. 10. As shown in FIG. 17, the CNTRL_OUT signal from the microcontroller U3 is provided to a relay component (generally depicted by a dotted-line box 304). Depending on the state of the CNTRL_OUT signal, a switch in the relay component can provide ON or OFF condition for AC power to the electrical motor (via connector 306). For example, a switching configuration where the switch is at the “1” position, AC power is not provided to the connector 306; whereas the switch at the “2” position results in the AC power from the source 300 being delivered to the connector 306.

Table 1 lists non-limiting examples of some of the components that are shown in the schematic circuit diagram 290 of FIG. 17. Quantities listed (e.g., voltages, currents, resistances, capacitances, etc.) are approximate values, and suitable substitutions of one or more components may be made by one of ordinary skill in the art. Similarly, components whose examples are not specifically listed in Table 1 can also be implemented by one of ordinary skill in the art.

TABLE 1 Component Part Number Description Manufacturer C1 C0805C105K8RACTV Cap, 1uF, 25V, 0805 Kemet C2 140-XRL25V470-RC Cap, 470uF, 25V Elct Mouser C3, 4 08053C103KAT2A Cap, .01uF, 25V, 0805 Avx C5, 6 08053C472KAT2A Cap, 4700pF, 25V Avx C7, 9, 10 1808AA101KAT1A Cap, 100pF, 1000V 1808 Avx C8 08051A330JAT2A Cap, 47pF, 50V Avx D1, 2, 3 583-IN4001 Diode, 1 Amp, 50V Mouser F1 PPL04851_A2B2 CPTC Thermistor Tics K1 655-T90S1D12-12 Relay, 30 Amp Mouser K2 9007-05-00 Reed Relay Mouser P5 WM26810-ND Header, 2 × 5 .100 Grid Digi-Key Q1, 2 BC846BMTF Transistor, NPN Fairchild R1 260-62K-RC Res, 62K, 1W, 0805 Xicon R2, 3 260-10K-RC Res, 10K, 1W, 0805 Xicon R4, 5, 7, 8 260-2.0K-RC Res, 2K, 1W, 0805 Xicon R6, 9-13 260-100K-RC Res, 100K, 1W, 0805 Xicon T1 DST-2-24 or Equivalent Power Transformer Signal xfmr U1 MC78L05ACDR2G Regulator, 5V, SO8 On Semi U2 QT220 Dual Capacitance Sw, SSOP20 Quantum U3 PIC16F627A-1-SS Micro Processor Microchip

While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. For example, while some of the above embodiments have been described with reference to dewatering systems, the invention also applies to other types of systems that use electronic sensors in potentially dirty environments. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms. Furthermore, various omissions, substitutions, and changes in the form of the methods and systems described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the inventions. 

What is claimed is:
 1. A kit, comprising: a replacement cap dimensioned to replace an existing cap of a housing of a submersible water pump, the replacement cap defining an inner recess and an aperture extending from the inner recess to an outer surface of the replacement cap; one or more sensors configured to be mountable to the replacement cap, the one or more sensors having electrical leads dimensioned to extend through the aperture when the one or more sensors are mounted to the replacement cap, the one or more electrical sensors capable of generating respective sensing signals to indicate types of substance in contact with the respective sensors; a pump control circuit configured to be mountable to the replacement cap such that at least a portion of the pump control circuit is within the inner recess, the pump control circuit dimensioned such that when the replacement cap with the pump control circuit mounted thereto is secured to the housing, the pump control circuit is substantially within the housing.
 2. The kit of claim 1, further comprising a sealing component configured to facilitate a substantially water-tight seal for the pump control circuit when the replacement cap is secured to the housing.
 3. The kit of claim 1, further comprising a power connection kit configured to allow connection of the pump control circuit to a power source for the submersible water pump to thereby provide power to the pump control circuit.
 4. The kit of claim 1, further comprising a control output connection kit configured to facilitate switching on and off of the submersible water pump by the pump control circuit. 